Efficient sub-structures

ABSTRACT

A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.

BACKGROUND INFORMATION

1. Field

The present disclosure relates to efficient sub-structures. Moreparticularly, the present disclosure relates to parts that havehoneycomb-like structures that include different types of shapedopenings within the structure. Still more particularly, the presentdisclosure relates to efficient sub-structures for flight controlstructures of aircraft.

2. Background

Building parts with a honeycomb-like internal structure has been knownfor decades for both buildings and vehicles such as aircraft.Honeycomb-like structures make components lighter and may convey greaterstrength, in some cases. Due to manufacturing limitations,honeycomb-like structures for any given part are uniform in nature.Thus, for example, all honeycombs within a given part have the sameshape and size. The only way to vary honeycomb structures was to affixindividual parts together, each made with a different honeycombstructure.

SUMMARY

An embodiment of the present disclosure provides for a componentincluding a part comprising a honeycomb-like structure formed from atleast a seamless resin-infused fiber composite material. Thehoneycomb-like structure includes a first plurality of honeycomb-likecells, and a second plurality of honeycomb-like cells, different fromthe first plurality of honeycomb-like cells.

Another embodiment of the present disclosure also provides for a methodof manufacturing a part. The method includes using additivemanufacturing to form seamlessly, a first honeycomb-like structuretogether with a second honeycomb-like structure. The firsthoneycomb-like structure and the second honeycomb-like structure aredifferent.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a varying honeycomb-like structure depictedin accordance with an illustrative embodiment;

FIG. 2 is an illustration of another varying honeycomb-like structuredepicted in accordance with an illustrative embodiment;

FIG. 3 is an illustration of yet another varying honeycomb-likestructure depicted in accordance with an illustrative embodiment;

FIG. 4 is an illustration of varying wall thickness for walls of ahoneycomb-like structure depicted in accordance with an illustrativeembodiment;

FIG. 5 is an illustration of varying wall thicknesses and wall materialsfor walls of a honeycomb-like structure depicted in accordance with anillustrative embodiment;

FIG. 6 is an illustration of lightening holes for a honeycomb-likestructure depicted in accordance with an illustrative embodiment;

FIG. 7 is an illustration of an aircraft wing panel formed using ahoneycomb-like structure depicted in accordance with an illustrativeembodiment;

FIG. 8 is a block diagram of a component depicted in accordance with anillustrative embodiment; and

FIG. 9 is a flowchart of a method of manufacturing a component depictedin accordance with an illustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account that newefficient sub-structures for construction and for vehicles, as well asflight control structures, can be made using additive manufacturing(AM). Additive manufacturing can efficiently create a structure withintricate designs that are tailored to a specific engineeringapplication. For example, in the specific case of aircraft parts, ribsand spars can be built to meet specific load and stress conditions toreplace conventional ribs or spars with a full depth honeycomb coredesign.

As used herein the term “structure” refers to an overall object whichmay be unitary or made from parts. The term “sub-structure” refers to apart which is included in or intended for use in a larger structure.Unless otherwise stated, a sub-structure is intended to be a unitarycomponent which is not, itself, made from further sub-parts. The term“unitary” or “unitary construction” means that the object is created asa single contiguous thing and not assembled from parts or sub-parts.

The illustrative embodiments refer, in some cases, to aircraft parts,aircraft sub-structures, an aircraft as a structure, or parts used aspart of operating an aircraft. However, such examples are illustrativeonly and do not necessarily limit the claimed inventions. Theillustrative embodiments specifically contemplate structures andsub-structures used in other types of vehicles including but not limitedto helicopters, automobiles, boats, ships, submarines, tanks. Theillustrative embodiments also specifically contemplate other types ofstructures and sub-structures, such as those used in buildings or otherobjects. Thus, reference to an “aircraft” or part of an aircraft is onlyintended as a specific example of the illustrative embodiments withoutnecessarily limiting the claimed inventions.

The illustrative embodiments also provide for a much more efficientdesign that can save weight, and be tailored to meet specificengineering requirements aside from load or stress requirements. Forexample, sub-structures can be made with a high temperature epoxy orwith an aluminum alloy, or a combination of both materials. Aluminum weband high temperature plastic interfaces, such as feet, allow thesub-structure to be bonded to a carbon fiber skin without galvaniccorrosion issues.

The illustrative embodiments recognize and take into account thatcurrent sub-structure designs, which in the specific example of vehicleparts could include spar, ribs, stringers, and other skin stiffeners,have design limitations and are undesirably heavy. The additivemanufacturing techniques of the illustrative embodiments allow for atailored design and more efficient load transfer while in use. Theillustrative embodiments recognize and take into account that, using thetechniques described herein, sub-structures can be designed to spreadthe load (like a leaf or web) and highly loaded areas can be reinforcedby increasing the thickness of the web.

Lightening holes can also be provided in the sub-structures to saveweight. For example, when web thickness is increased, sub-structureweight is also increased. Lightening holes can be placed in thesub-structures without compromising the stiffness of the sub-structure.Also, with lightening holes, when the sub-structure is bonded to theskin, usually in an autoclave or oven, the air inside the sub-structureis not trapped within one cell, but can move within the sub-structure.The ability for air to move helps stabilize the entire sub-structure.Additionally, this type of structure allows the introduction ofadditional pressure into the sub-structure to help prevent it fromcollapsing during curing.

Thus, the illustrative embodiments provide for a honeycomb-likestructure having different size cells, different size walls, anddifferent shaped cells. Portions of the cell wall can be thicker thanothers, where the thickness would provide a desired increase instrength. The increased thickness can correspond to the different cellsizes. A combination of materials may also be used, for example, acombination of epoxy and metal such as Aluminum. This structure can beused in both non-aerospace structures, as well as aerospace structures.

In a specific example, an exemplary cell structure could be applied toan aircraft wing. In this example, the outer walls are the thickestportion, the outer walls extending longitudinally. Moving inwardly fromboth walls, the largest cell structure evolves into smaller cellstructures towards the middle of the cell structure. The wallthicknesses also change from thicker to thinner moving inwardly. Thecell structure can be a mirror image about a centerline extendinglongitudinally.

Having regionally customized cells will allow for tailored strength andweight. The variable cell structure can also be applied to ailerons,spoilers, and flaps.

The thickness of the walls can vary also in a top to bottom fashionwhere in one example, the top and bottom of the honeycomb is thicker.This variation is particularly useful where the top and bottom are incontact with a covering or flat surface where the increased thicknessprovides a larger contact area for fastening or bonding.

Additionally, the material of the cell walls can vary. In one example,the thickened portion is made of high temperature epoxy, while the webis metal. To lighten the structure, holes of varying size may be locatedwithin the web.

Thus, the illustrative embodiments provide for a honeycomb-likestructure having different cells types. The different cell type caninclude different sized cells. The different cell types can includedifferent size walls. The different cell types can include differentshaped cells. The different sized walls can vary in thickness from onesidewall towards an opposing sidewall. An outer cell wall portion mayhave the same height as an inner cell wall portion, but may be thickerat the outer cell wall portion. The different sized walls can vary,having increased thickness at either or both, the top or bottomportions. The structure may include lightening holes. The cells and cellwalls may be formed from different materials.

The illustrative embodiments also recognize and take into account thatcurrent honeycomb-like structured objects cannot be varied. Whiledifferent parts with different honeycomb-like shapes could be attachedto each other, it is not possible to create a monolithic object having ahoneycomb-like structure with varying cells. The illustrativeembodiments also recognize and take into account that using a monolithicconstruction limits moisture up-take, which is a serious concern forhoneycombed structures.

The illustrative embodiments also recognize and take into account that,when using 3D printing or additive manufacturing, the thickness of thewall can be changed as desired. The foot can be slightly thicker orflare out and the walls can be thicker to support more of a load. Awider foot gives more bonding surface to which the skin panel can bebonded. As the cell pitch and/or density is changed, the cell wallthickness can be changed. In a specific example, the cell wall can be0.020 inches to 0.050 inches in thickness, as the pitch grows, to 1 inchapart or more, and the foot flares out to 0.100 inches wide. The cellpattern can change from hexagonal to any other desired shape.

FIG. 1 is an illustration of a varying honeycomb-like structure depictedin accordance with an illustrative embodiment. Honeycomb-like structure100 is an example of a honeycomb-like structure that may be used whenforming a component or sub-structure. Honeycomb-like structure 100 is aplurality of cells having a mixture of three different cell pitches. Thepitch of a cell is defined by the width (W), across one cell.Honeycomb-like structure 100 has three groups of cells with threedifferent pitches: first plurality of cells 102, second plurality ofcells 104, and third plurality of cells 106. In this particularillustrative embodiment, each group of cells is adjacent the other alonglongitudinal axis 114 of honeycomb-like structure 100.

The first pitch of first plurality of cells 102 is width W 108. Thesecond pitch of second plurality of cells 104 is width W2 110. Thesecond pitch is smaller than the first pitch. The third pitch of thirdplurality of cells 106 is width W3 112. The third pitch is smaller thanthe second pitch. The thicknesses of the walls of each type of cell mayvary. For example, the walls of first plurality of cells 102 may bethicker than the walls of second plurality of cells 104, which in turnmay be thicker than the walls of third plurality of cells 106. However,this pattern may be varied. For example, the smaller cells may have thethickest walls, and many other variations are possible.

Because the pitches vary between groups of cells, interstitial spaces,such as interstitial space 116 and interstitial space 118, are formedbetween different groups of cell type. The interstitial spaces may befilled with a material, if desirable.

Honeycomb-like structure 100 may be manufactured using additivemanufacturing techniques, such as, but not limited to, 3D printing.Additive manufacturing techniques allow the creation of uniquestructures without extensive machining. The materials used in additivemanufacturing may provide for high temperature, high strengthstructures. Examples of such materials include epoxy, aluminum, and moreimportantly, combinations thereof within a single honeycomb-likestructure.

FIG. 2 is an illustration of another varying honeycomb-like structuredepicted in accordance with an illustrative embodiment. Honeycomb-likestructure 200 may be a variation of honeycomb-like structure 100 ofFIG. 1. Honeycomb-like structure 200 may be a variable core, whichincludes multiple adjoining sets of the same type of honeycomb-likestructure. Thus, for example, cell 202 may be of a first size; cell 204,cell 206, and cell 208 may all be of a second size; and cell 210 may beof a third size.

Honeycomb-like structure 200 may be suitable for small flight controlsurfaces, such as ailerons, spoilers, and flaps. Honeycomb-likestructure 200 may be manufactured using additive manufacturingtechniques. Honeycomb-like structure 200 may include a skin panel on oneor both surfaces into and out of the page of FIG. 2. The skin panel maybe a solid laminate and can be resin-infused and cured in an oven.Honeycomb-like structure 200 may be a monolithic structure created usingadditive manufacturing techniques, or may be bonded parts (such asbonding skin panels to a monolithically constructed honeycomb-likestructure, such as honeycomb-like structure 200).

FIG. 3 is an illustration of yet another varying honeycomb-likestructure depicted in accordance with an illustrative embodiment.Honeycomb-like structure 300 may be a side view of honeycomb-likestructure 200 of FIG. 2, with skin panels attached. Thus, for example,the same cell structure shown in FIG. 2 is present in FIG. 3, but inFIG. 3 skin panel 302 and skin panel 304 are visible.

FIG. 4 is an illustration of varying wall thicknesses for walls of ahoneycomb-like structure depicted in accordance with an illustrativeembodiment. Wall 400 may be the wall of a honeycomb cell in ahoneycomb-like structure, such as honeycomb-like structure 100 of FIG.1, honeycomb-like structure 200 of FIG. 2, or honeycomb-like structure300 of FIG. 3.

Wall 400 includes three sections, including first section 402, secondsection 404, and third section 406. First section 402 and third section406 may flare outwardly from second section 404 in order to provideadditional bonding strength with respect to skin panels that may bebonded to the ends of first section 402 and third section 406. Secondsection 404 may be thinner in order to reduce the weight of the overallstructure, while not sacrificing the overall strength of the structure.In other illustrative embodiments, second section 404 may have differentshapes, such as, for example, a convex or concave shape.

FIG. 5 is an illustration of varying wall thickness and wall materialfor walls of a honeycomb-like structure depicted in accordance with anillustrative embodiment. Wall 500 may be the wall of a honeycomb cell ina honeycomb-like structure, such as honeycomb-like structure 100 of FIG.1, honeycomb-like structure 200 of FIG. 2, or honeycomb-like structure300 of FIG. 3. Wall 500 may be a variation of wall 400 of FIG. 4.

Wall 500 includes three sections, including first section 502, secondsection 504, and third section 506. First section 502 and third section506 may flare outwardly from second section 504 in order to provideadditional bonding strength, with respect to the skin panels that may bebonded to the ends of first section 502 and third section 506. Secondsection 504 may be thinner in order to reduce the weight of the overallstructure, while not sacrificing the overall strength of the structure.In other illustrative embodiments, second section 504 may have differentshapes, such as, for example, a convex or concave shape.

One difference between wall 400 and wall 500 is that second section 504of wall 500 may be formed from a different material than first section502 and third section 506. For example, first section 502 and thirdsection 506 may be formed from a high temperature epoxy or plastic inorder to more easily bond wall 500 to a composite skin panel, such as acarbon fiber reinforced panel. However, second section 504 may be formedfrom a metal, such as but not limited to aluminum, in order tostrengthen and/or lighten the overall honeycomb-like structure. In aparticular example, aluminum may increase the stiffness of wall 500,thereby increasing the overall strength of a component formed usinghoneycombs having walls, such as wall 500.

FIG. 6 is an illustration of lightening holes for a honeycomb-likestructure, in accordance with an illustrative embodiment. Panel 600 maybe, for example, a top view of a component, such as honeycomb-likestructure 300 of FIG. 3. Lightening holes, such as hole 602, hole 604,and hole 606, may be included in panel 600.

Each of these holes may extend, completely or partially, through thecomponent. For example, each of these holes may extend only through askin panel, exposing the honeycomb-like structure underneath. In anotherexample, the holes may correspond to spaces within the honeycomb-likestructure. In still another example, the holes may effectively removewalls within the honeycomb-like structure, thereby extending all the waythrough the component in question. Many other variations are possible.

The density of holes, the size of holes, and the pattern of holes mayvary over the surface of panel 600. Thus, for example, first group ofholes 608 may be three holes of a first size arranged in a single row ofthree holes. Second group of holes 610 may be of a second size, largerthan the first size, and arranged in groups of four in two rows of two.Third group of holes 612 may be of a third size, larger than the secondsize, and arranged in groups of six in two rows of three. Many othervariations are possible from the example shown in FIG. 6.

FIG. 7 is an illustration of an aircraft wing panel formed using ahoneycomb-like structure depicted in accordance with an illustrativeembodiment. Wing 700 is an example of a component that can beconstructed using a honeycomb-like structure, such as honeycomb-likestructure 100 of FIG. 1, honeycomb-like structure 200 of FIG. 2, orhoneycomb-like structure 300 of FIG. 3. The walls of the honeycomb-likestructure forming wing 700 may vary as described with respect to FIG. 4or FIG. 5. Lightening holes, such as those shown in FIG. 6, optionallymay be provided in wing 700.

Some or all of wing 700 may include a honeycomb-like structure, such ashoneycomb-like structure 702. In this particular illustrativeembodiment, honeycomb-like structure 702 is the same pattern ashoneycomb-like structure 300 of FIG. 3, but other honeycomb-likestructures are possible. The walls of each structure may vary, such asshown in FIG. 4 and FIG. 5.

Conventional wing structure or control surfaces (aileron, rudder,elevator, flap, spoiler, etc.) have spar and ribs as sub-structure. Skinpanels are either stiffened with stringers or a honeycomb core. A fulldepth core is also used on some structures like the flap, spoiler andaileron, if it has weight advantage.

Thus, for large flight control surfaces, such as a rudder, an elevator,or the like, or for a small wing, the illustrative embodimentscontemplate replacing a honeycomb core stiffened skin panel with alaminate skin panel. Likewise, honeycomb core stiffened ribs may bereplaced with a variable rib and sub-structure created using additivemanufacturing. The skin panel, in some instances, may be resin-infused,attached to the honeycomb-like structure, and then cured in an oven.

In smaller flight control surfaces, such as spoilers, flaps, ailerons,and the like, a full depth core may be used. Different core densitiesmay be used in the same monolithic structure, or perhaps differentstructures spliced together, as desired to reinforce the part. Manyother variations are possible.

FIG. 8 is a block diagram of a component depicted in accordance with anillustrative embodiment. Component 800 may be a variation of asub-component with a honeycomb-like structure, as described above. Forexample, wing 700 with honeycomb-like structure 702 may be a specificexample of component 800.

Component 800 may be part 802. Part 802 is distinguished from component800, as part 802 may be a sub-part of component 800, but in otherillustrative embodiments may be the entirety of component 800.

In any case, component 800 may be part 802 including honeycomb-likestructure 804 formed from at least a seamless resin-infused fibercomposite material. Honeycomb-like structure 804 includes firstplurality of honeycomb-like cells 806. Honeycomb-like structure 804 alsoincludes second plurality of honeycomb-like cells 808, different thanfirst plurality of honeycomb-like cells 806. Optionally, honeycomb-likestructure 804 may include third plurality of honeycomb-like cells 810,different from both first plurality of honeycomb-like cells 806 andsecond plurality of honeycomb-like cells 808.

Honeycomb-like structure 804 may be varied. For example, in anillustrative embodiment, first plurality of honeycomb-like cells 806 maybe intermixed with second plurality of honeycomb-like cells 808 suchthat any given honeycomb-like cell of the first plurality is adjacent toat least one honeycomb-like cell of the second plurality. In anotherexample, the first cells of first plurality of honeycomb-like cells 806may be larger than the second cells of second plurality ofhoneycomb-like cells 808.

In still another illustrative embodiment, the first cells of firstplurality of honeycomb-like cells 806 may have different wallthicknesses relative to the second cells of second plurality ofhoneycomb-like cells 808. In yet another illustrative embodiment, thefirst cells of first plurality of honeycomb-like cells 806 may havedifferent shapes relative to the second cells of second plurality ofhoneycomb-like cells 808.

In still another illustrative embodiment, the first cells of firstplurality of honeycomb-like cells 806 may have different wallthicknesses than the second cells of second plurality of honeycomb-likecells 808, and different sized walls may vary in thickness from onesidewall to an opposing sidewall. In this case, an outer cell wallportion may have a same height as an inner cell wall portion but isthicker at the outer cell wall portion.

In a different illustrative embodiment, the first cells of firstplurality of honeycomb-like cells 806 may have walls that have differentvarying thicknesses at, either or both of, the top or bottom portions ofthe walls, relative to the second cells of second plurality ofhoneycomb-like cells 808. In yet a different illustrative embodiment,hole 812 may be disposed in honeycomb-like structure 804 wherehoneycomb-like structures are absent.

In still another illustrative embodiment, first plurality ofhoneycomb-like cells 806 may be made from a first material, and secondplurality of honeycomb-like cells 808 may be made from a secondmaterial, different than the first material. In another variation, bothfirst plurality of honeycomb-like cells 806 and second plurality ofhoneycomb-like cells 808 may be made from a first material along a firstportion, and a second material along a second portion. In this case, thesecond material may be different than the first material. In stillanother variation, the second ones of second plurality of honeycomb-likecells 808 are disposed inside the first ones of first plurality ofhoneycomb-like cells 806.

Still other variations are possible. For example, component 800 may alsoinclude first surface 814 and second surface 816, opposite of firstsurface 814. In this case, honeycomb-like structure 804 is sandwichedbetween first surface 814 and second surface 816.

In a further variation, first surface 814 and second surface 816 may bemade from a first material, wherein the honeycomb-like structurecomprises at least a second material different than the first material.In this case, first surface 814 and second surface 816 may form aunitary construction with honeycomb-like structure 804. As a furthervariation, first plurality of honeycomb-like cells 806 may be made fromthe second material, and second plurality of honeycomb-like cells 808may be made from a third material different than both the first materialand the second material.

In yet another variation, the part may be an aircraft part. Still moreparticularly, the aircraft part may a wing made as a unitary piece. Theaircraft part could also be a unitary fuselage, or a panel of multiplepanels and components that make up a fuselage. The aircraft part couldalso be a spar, a stringer, or any other component used in an aircraft.

Many other variations are possible, as additive manufacturing can beused to make custom or unique honeycomb-like cell structures of varyingcell types, cell wall thicknesses, differing materials, and othervariations. Thus, the illustrative embodiments described above do notnecessarily limit the claimed inventions or the other examples describedherein.

FIG. 9 is a flowchart of a method of manufacturing a component depictedin accordance with an illustrative embodiment. Method 900 may be used tocreate the various structures described with respect to FIG. 1 throughFIG. 8. Method 900 may be characterized as a method of manufacturing apart.

Method 900 may be broadly characterized as using additive manufacturingto form seamlessly, a first honeycomb-like structure together with asecond honeycomb-like structure, wherein the first honeycomb-likestructure and the second honeycomb-like structure are different(operation 904). Optionally, prior to forming the first honeycomb-likestructure and the second honeycomb-like structure, forming a first panelusing additive manufacturing, and wherein forming the firsthoneycomb-like structure and the second honeycomb-like structure isperformed onto the first panel (operation 902). Optionally, afterforming the first honeycomb-like structure and the second honeycomb-likestructure, forming a second panel using additive manufacturing onto thefirst honeycomb-like structure and the second honeycomb-like structure(operation 906). Method 900 may be further varied. For example, thefirst walls of the first cells of the first honeycomb-like structure mayhave varying thicknesses and may be thinnest near the center pointsbetween the first panel and the second panel. In another example, thefirst honeycomb-like structure may be made from a first material. Thesecond honeycomb-like structure may be made from a second material. Thefirst material and the second material may be different. In a stilldifferent example, the first cells of the first honeycomb-like structuremay be different in shape, relative to the second cells of the secondhoneycomb-like structure. The upper and lower skin of the airplanestructure may be laid up separately, and then bonded to thehoneycomb-like structure in an autoclave or oven. The skins may bepre-cured or may be un-cured when bonded to the honeycomb-likestructure.

More or fewer operations may be added. For example, method 900 may bepart of an aircraft manufacture or maintenance operation where parts arereplaced or maintained. Thus, the illustrative embodiments describedabove do not necessarily limit the claimed inventions or other examplesprovided herein.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features, as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications, as are suited to the particular usecontemplated.

What is claimed is:
 1. A component comprising: a part comprising ahoneycomb-like structure attached to a first surface, the first surfaceformed from at least a seamless resin-infused fiber composite material,wherein the honeycomb-like structure comprises: a first plurality ofcells; and a second plurality of cells, different than the firstplurality of cells; wherein first cells of the first plurality of cellshave walls that have different varying thicknesses, at either or bothof, a top or bottom portions of the walls, relative to second cells ofthe second plurality of cells.
 2. The component of claim 1 furthercomprising: a third plurality of cells, different from both the firstplurality of cells and the second plurality of cells.
 3. The componentof claim 1, wherein the first plurality of cells is intermixed with thesecond plurality of cells such that any given cell of the firstplurality of cells is adjacent to at least one cell of the secondplurality of cells.
 4. The component of claim 1, wherein the first cellsof the first plurality of cells are larger than the second cells of thesecond plurality of cells.
 5. The component of claim 1, wherein thefirst cells of the first plurality of cells have different shapesrelative to the second cells of the second plurality of cells.
 6. Thecomponent of claim 1, wherein the walls are different sized walls thatvary in thickness from one sidewall to an opposing sidewall, and whereinan outer cell wall portion has a same height as an inner cell wallportion but is thicker at the outer cell wall portion.
 7. The componentof claim 1 further comprising: a hole disposed in the honeycomb-likestructure where honeycombs are absent.
 8. The component of claim 1,wherein the first plurality of cells comprises a first material, andwherein the second plurality of cells comprises a second materialdifferent than the first material.
 9. The component of claim 1, whereinboth the first plurality of cells and the second plurality of cellscomprise a first material along a first portion and a second materialalong a second portion, and wherein the second material is differentthan the first material.
 10. The component of claim 1, wherein secondones of the second plurality of cells are disposed inside first ones ofthe first plurality of cells.
 11. The component of claim 1 furthercomprising: a second surface opposite the first surface, wherein thehoneycomb-like structure is sandwiched between the first surface and thesecond surface.
 12. The component of claim 11, wherein the first surfaceand the second surface comprise a first material, wherein thehoneycomb-like structure comprises at least a second material differentthan the first material, and wherein the first surface and the secondsurface form a unitary construction with the honeycomb-like structure.13. The component of claim 12, wherein the first plurality of cellscomprises the second material, and wherein the second plurality of cellscomprises a third material different than both the first material andthe second material.
 14. The component of claim 1, wherein the partcomprises an aircraft part.
 15. The component of claim 14, wherein theaircraft part comprises a wing made as a unitary piece.
 16. A method ofmanufacturing a part comprising a honeycomb-like structure attached to afirst panel, the first panel formed from at least a seamlessresin-infused fiber composite material, the method comprising: forming afirst honeycomb-like structure together with a second honeycomb-likestructure, wherein the first honeycomb-like structure has first cellsand the second honeycomb-like structure has second cells, wherein thefirst cells have walls that have different varying thicknesses, ateither or both of, a top or bottom portions of the walls, relative tothe second cells.
 17. The method of claim 16 further comprising: priorto forming the first honeycomb-like structure and the secondhoneycomb-like structure, forming the first panel, and wherein formingthe first honeycomb-like structure and the second honeycomb-likestructure is performed onto the first panel; and after forming the firsthoneycomb-like structure and the second honeycomb-like structure,forming a second panel onto the first honeycomb-like structure and thesecond honeycomb-like structure.
 18. The method of claim 17, wherein:the part comprises an aircraft part; first walls of the first cells ofthe first honeycomb-like structure have the varying thicknesses and arethinnest near center points between the first panel and the secondpanel; the first honeycomb-like structure comprises a first material,wherein the second honeycomb-like structure comprises a second material,the first material and the second material being different; and thefirst cells of the first honeycomb-like structure are different in shaperelative to the second cells of the second honeycomb-like structure. 19.A component comprising: a part comprising a honeycomb-like structureattached to a first surface, the first surface formed from at least aseamless resin-infused fiber composite material, wherein thehoneycomb-like structure comprises: a first plurality of cells; and asecond plurality of cells, different than the first plurality of cells;wherein both the first plurality of cells and the second plurality ofcells comprise a first material along a first portion and a secondmaterial along a second portion, and wherein the second material isdifferent than the first material.